阅读说明：本技术 电动工具 (Electric tool ) 是由 米田文生 花村贤治 中原雅之 于 2020-01-30 设计创作，主要内容包括：本发明的目的是提供一种电动工具,其被配置为增加电动马达的转数。电动工具(1)包括AC马达(15)(电动马达)和控制单元(4)。AC马达(15)包括永磁体(131)和线圈(141)。控制单元(4)被配置为对AC马达(15)的操作进行控制。控制单元(4)所进行的控制包括弱磁控制。在弱磁控制中,控制单元(4)使弱磁电流流经线圈(141)。弱磁电流是用于在线圈(141)中产生使永磁体(131)的磁通削弱的磁通的电流。(An object of the present invention is to provide an electric power tool configured to increase the number of revolutions of an electric motor. The electric tool (1) includes an AC motor (15) (electric motor) and a control unit (4). The AC motor (15) includes a permanent magnet (131) and a coil (141). The control unit (4) is configured to control the operation of the AC motor (15). The control performed by the control unit (4) includes field weakening control. In the field weakening control, the control unit (4) causes a field weakening current to flow through the coil (141). The field weakening current is a current for generating a magnetic flux in the coil (141) that weakens the magnetic flux of the permanent magnet (131).)

1. A power tool, comprising:

an electric motor including a permanent magnet and a coil; and

a control unit configured to control operation of the electric motor,

wherein the control by the control unit includes field weakening control by which a field weakening current, which is a current for generating a magnetic flux in the coil that weakens the magnetic flux of the permanent magnet, flows through the coil.

2. The power tool according to claim 1,

the control by the control unit includes:

the flux weakening control, and

a normal control in which the field-weakening current is not caused to flow through the coil, an

The control performed by the control unit is the field weakening control in a case where a predetermined switching condition is satisfied.

3. The power tool according to claim 2,

the switching condition includes a condition that the electric motor is operating in a high speed range.

4. The power tool according to claim 3,

the high speed range is an operation range in which the number of rotations of the electric motor is greater than or equal to a predetermined number of rotations.

5. The electric power tool according to claim 3 or 4,

the control unit is configured to control electric power to be supplied to the electric motor by PWM control, an

The high speed range is an operating range in which the duty ratio of the PWM control is greater than or equal to a predetermined value.

6. The electric power tool according to any one of claims 2 to 5,

the switching condition includes a condition that a value of a torque current flowing through the coil is less than or equal to a predetermined current value.

7. The electric power tool according to any one of claims 1 to 6,

the control unit has a function for changing the magnitude of the field weakening current in the field weakening control.

8. The power tool according to claim 7,

the control unit is configured to perform gradual increase control of increasing an absolute value of the field weakening current with the passage of time, in a case where a predetermined increase condition is satisfied in the field weakening control.

9. The electric power tool according to claim 7 or 8,

the control unit is configured to perform, in the field weakening control, gradual decrease control that decreases an absolute value of the field weakening current with the passage of time, in a case where a predetermined decrease condition is satisfied.

10. The power tool according to claim 8,

the control unit is configured to perform, in the field weakening control, gradual decrease control that decreases an absolute value of the field weakening current with elapse of time in a case where a predetermined decrease condition is satisfied, the predetermined decrease condition being different from the predetermined increase condition, a rate of change of the field weakening current in the gradual decrease control being smaller than a rate of change of the field weakening current in the gradual increase control.

Technical Field

The present invention relates generally to power tools, and more particularly to power tools including an electric motor.

Background

An electric tool configured to control the number of rotations of an electric motor is known (for example, patent document 1). The electric power tool described in patent document 1 includes a brushless DC motor (electric motor), a battery voltage detector, a rotational position detector, and a control unit. The battery voltage detector is configured to detect a voltage of a battery for driving the brushless DC motor. The rotational position detector is configured to detect a rotational position of the brushless DC motor. The control unit is configured to control a drive output to the brushless DC motor based on a signal from the rotational position detector. The control unit is configured to control a conduction angle or an advance angle to the brushless DC motor such that a number of revolutions or a conduction current of the brushless DC motor is a target value corresponding to the battery voltage detected by the battery voltage detector, when controlling the drive output to the brushless DC motor.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open No. 2014-144496

Disclosure of Invention

An object of the present invention is to provide an electric tool configured to increase the number of revolutions of an electric motor.

An electric motor according to an aspect of the present invention includes an electric motor and a control unit. The electric motor includes a permanent magnet and a coil. The control unit is configured to control operation of the electric motor. The control by the control unit includes field weakening control by which a field weakening current is caused to flow through the coil. The field weakening current is a current for generating a magnetic flux in the coil that weakens the magnetic flux of the permanent magnet.

Drawings

Fig. 1 is a block diagram showing a power tool according to an embodiment;

fig. 2 is a schematic view schematically showing the electric power tool;

fig. 3 is a flowchart showing an operation example of the electric power tool; and

fig. 4 is a graph showing an operation example of the electric power tool.

Detailed Description

An embodiment of the power tool 1 will now be described in detail with reference to the accompanying drawings. Note that the embodiments to be described below are merely typical embodiments among various embodiments of the present invention, and should not be construed as limiting. Rather, the exemplary embodiment can be easily modified in various ways according to design choice or any other factors without departing from the scope of the present invention. Further, fig. 2 to be referred to in the following description of the embodiments is a schematic diagram. That is, the ratio of the sizes (including thicknesses) of the respective constituent elements shown in fig. 2 does not always reflect the actual size ratio of these constituent elements.

(1) Overview

The electric power tool 1 according to the exemplary embodiment may be used as an impact screwdriver, a drill screwdriver, or an impact wrench. As shown in fig. 1, the electric power tool 1 includes an AC (alternating current) motor 15 (electric motor) and a control unit 4. The AC motor 15 may be, for example, a brushless motor. In particular, the AC motor 15 according to the present embodiment is a synchronous motor, and more specifically, a Permanent Magnet Synchronous Motor (PMSM). The control unit 4 controls the operation of the AC motor 15.

The AC motor 15 includes a rotor 13 having permanent magnets 131 and a stator 14 having coils 141. The rotor 13 includes an output shaft 16. The electromagnetic interaction between the coils 141 and the permanent magnets 131 causes the rotor 13 to rotate relative to the stator 14. The control unit 4 performs vector control for controlling the field weakening current (d-axis current) supplied to the AC motor 15 and the torque current (q-axis current) supplied to the AC motor 15 independently of each other. The control performed by the control unit 4 includes field weakening control by vector control. In the field weakening control, the control unit 4 causes a field weakening current (d-axis current) to flow through the coil 141 of the AC motor 15. The field weakening current generates a magnetic flux (field weakening) in the coil 141, which weakens the magnetic flux of the permanent magnet 131. In other words, the weak magnetic current generates a magnetic flux in the coil 141 in a direction opposite to that of the magnetic flux of the permanent magnet 131. This increases the number of revolutions of the AC motor 15 (the number of revolutions of the output shaft 16).

The control performed by the control unit 4 also includes conventional control. In the normal control, the control unit 4 does not flow a weak magnetic current through the coil 141. That is, the current flowing through the coil 141 in the conventional control is only a torque current (q-axis current). In the case where the torque current of the AC motor 15 is relatively large (for example, the magnitude of the torque current exceeds a predetermined value), the control unit 4 changes its control from the field-weakening control to the normal control. Therefore, in the case where the AC motor 15 requires a relatively large torque, the conventional control provides a relatively large torque.

(2) Electric tool

As shown in fig. 2, the electric power tool 1 includes an AC motor 15, a power source 32, a driving force transmission mechanism 18, an impact mechanism 17, a socket 23, a trigger 29, a control unit 4, a torque measurement unit 26, a bit rotation measurement unit 25, and a motor rotation measurement unit 27. In addition, the electric power tool 1 includes a tip tool.

The impact mechanism 17 has an output shaft 21. The output shaft 21 is a member rotated by the driving force transmitted from the AC motor 15. The socket 23 is a member fixed to the output shaft 21 and to which a front end tool is detachably attached. The electric power tool 1 is a tool for driving a tip tool with a driving force supplied from an AC motor 15. For example, the front end tool (hereinafter also referred to as "drill") may be a screwdriver or a drill. The front end tool is selected from various types of front end tools according to the intended use, and is attached to the socket 23 to perform some type of machining. Alternatively, the front end tool may be directly attached to the output shaft 21.

The AC motor 15 is a drive source for driving the tip tool. The AC motor 15 includes an output shaft 16 for outputting a rotational driving force. The power supply 32 is an AC power supply for supplying current for driving the AC motor 15. The power supply 32 includes a single or a plurality of secondary batteries. The driving force transmission mechanism 18 adjusts the rotational driving force of the AC motor 15 and outputs a desired torque. The drive force transmission mechanism 18 includes a drive shaft 22 as its output member.

The drive shaft 22 of the drive force transmission mechanism 18 is connected to the impact mechanism 17. The impact mechanism 17 converts the rotational driving force supplied from the AC motor 15 via the driving force transmission mechanism 18 into a pulse torque, thereby generating an impact force. The impact mechanism 17 includes a hammer 19, an anvil 20, an output shaft 21, and a spring 24. The hammer 19 is attached to a drive shaft 22 of the drive force transmission mechanism 18 via a cam mechanism. The anvil 20 is coupled to the hammer 19 and rotates together with the hammer 19. The spring 24 biases the hammer 19 toward the anvil 20. The anvil 20 is integrally formed with the output shaft 21. Alternatively, the anvil 20 may be formed separately from the output shaft 21 and fixed to the output shaft 21.

Unless a load (torque) of a magnitude greater than or equal to a predetermined value is applied to the output shaft 21, the drive shaft 22 and the hammer 19, which are coupled together via the cam mechanism, rotate together with each other, and in addition, the hammer 19 and the anvil 20 rotate together with each other. Accordingly, the output shaft 21 integrally formed with the anvil 20 rotates accordingly. On the other hand, if a load of magnitude greater than or equal to the predetermined value is applied to the output shaft 21, the hammer 19 moves rearward (i.e., away from the anvil 20) against the spring 24 while being adjusted by the cam mechanism. At a point of time when the hammer 19 is decoupled from the anvil 20, the hammer 19 starts moving forward while rotating, thereby applying an impact force to the anvil 20 in the rotating direction and thereby rotating the output shaft 21.

The trigger 29 is an operation member for receiving an operation command for controlling the rotation of the AC motor 15. The ON/OFF (ON/OFF) state of the AC motor 15 can be switched by pulling the trigger 29. In addition, the rotational speed of the output shaft 21, that is, the rotational speed of the AC motor 15 can be adjusted by a manipulated variable indicating the depth to which the trigger 29 is pulled. Specifically, the larger the manipulated variable, the higher the rotational speed of the AC motor 15 becomes. The control unit 4 starts or stops rotating the AC motor 15 and controls the rotational speed of the AC motor 15 according to a manipulated variable indicating the depth to which the trigger 29 is pulled. In this electric power tool 1, a front end tool is attached to the socket 23. Controlling the rotational speed of the AC motor 15 by operating the trigger 29 enables the rotational speed of the front end tool to be controlled.

The electric power tool 1 according to the present embodiment includes the socket 23, thereby making the tip tool replaceable according to the intended use. However, the front end tool need not be replaceable. Alternatively, the electric power tool 1 may also be designed to allow only a specific type of front-end tool to be used.

The torque measuring unit 26 measures the operating torque of the AC motor 15. The torque measuring unit 26 may be, for example, a magnetostrictive strain sensor that can detect torsional strain. The magnetostrictive strain sensor causes a coil provided in a non-rotating portion of the AC motor 15 to detect a change in magnetic permeability corresponding to strain caused by applying torque to the output shaft 16 of the AC motor 15, and outputs a voltage signal having a magnitude proportional to the magnitude of the strain.

The bit rotation measuring unit 25 measures the rotation angle of the output shaft 21. In this case, the rotation angle of the output shaft 21 is equal to the rotation angle of the tip end tool (drill). As the drill rotation measuring unit 25, for example, an optical encoder or a magnetic encoder may be used.

The motor rotation measuring unit 27 measures the rotation angle of the AC motor 15. As the motor rotation measuring unit 27, for example, an optical encoder or a magnetic encoder can be used.

(3) Control unit

The control unit 4 comprises a computer system comprising one or more processors and memory. At least a part of the functions of the control unit 4 is performed by causing a processor of the computer system to execute a program stored in a memory of the computer system. The program may be stored in a memory. The program may also be downloaded via a telecommunication network such as the internet or distributed after being stored in a non-transitory storage medium such as a memory card.

The control performed by the control unit 4 includes field weakening control and regular control. In the field weakening control, the control unit 4 causes a field weakening current to flow from the inverter circuit section 51 through the coil 141 of the AC motor 15. In the normal control, the control unit 4 does not cause a field-weakening current to flow from the inverter circuit section 51 through the coil 141. In the case where a switching condition described later is satisfied, the control performed by the control unit 4 is field weakening control. The conventional control is control performed in such a manner: the command value (target value) cid1 of the weak magnetic current is set to 0, and the weak magnetic current converges toward the command value cid 1. The field weakening control is control performed by: the command value cid1 of the weak magnetic current is set to be greater than 0, and the weak magnetic current converges toward the command value cid 1. In the case where the command value cid1 of the field weakening current is larger than 0, the field weakening current flows through the AC motor 15, thereby generating field weakening.

As shown in fig. 1, the control unit 4 includes a command value generation unit 41, a speed control unit 42, a current control unit 43, a first coordinate converter 44, a second coordinate converter 45, a magnetic flux control unit 46, an estimation unit 47, and a step-out detection unit 48. In addition, the electric power tool 1 further includes an inverter circuit portion 51 and a plurality of (e.g., two in the example shown in fig. 1) current sensors 61 and 62. The control unit 4 is used in conjunction with the inverter circuit section 51, and performs feedback control to control the operation of the AC motor 15.

Each of the plurality of current sensors 61 and 62 includes, for example, a hall element current sensor or a shunt resistance element. The plurality of current sensors 61 and 62 measure the current supplied from the power supply 32 to the AC motor 15 via the inverter circuit section 51. In the present embodiment, three-phase currents (i.e., a U-phase current, a V-phase current, and a W-phase current) are supplied to the AC motor 15. The plurality of current sensors 61 and 62 measure the currents of at least two phases. In fig. 1, a current sensor 61 measures the U-phase current and outputs a current measurement value i_u1, and the current sensor 62 measures the V-phase current and outputs a current measurement value i_v1。

The estimation unit 47 time-differentiates the rotation angle θ 1 of the AC motor 15 measured by the motor rotation measurement unit 27 to calculate the angular velocity ω 1 of the AC motor 15 (i.e., the angular velocity of the output shaft 16).

The second coordinate converter 45 measures current measurement values i measured by the plurality of current sensors 61 and 62 based on the rotation angle θ 1 of the AC motor 15 measured by the motor rotation measuring unit 27_u1 and i_v1, thereby calculating current measurement values id1 and iq 1. That is, the second coordinate converter 45 converts the current measurement value i corresponding to the two-phase current of the three-phase currents_u1 and i_v1 is transformed intoA current measurement id1 corresponding to the magnetic field component (d-axis current) and a current measurement iq1 corresponding to the torque component (q-axis current).

The command value generation unit 41 generates a command value c ω 1 of the angular velocity of the AC motor 15. The command value generation unit 41 generates the command value c ω 1 in accordance with, for example, the magnitude corresponding to the manipulated variable indicating the depth to which the trigger 29 (see fig. 2) is pulled. That is, as the manipulated variable increases, the command value generation unit 41 increases the command value c ω 1 of the angular velocity accordingly.

The speed control unit 42 generates the command value ciq1 based on the difference between the command value c ω 1 generated by the command value generation unit 41 and the angular speed ω 1 calculated by the estimation unit 47. The command value ciq1 is a command value that specifies the magnitude of the torque current (q-axis current) of the AC motor 15. The speed control unit 42 determines the command value ciq1 to reduce the difference between the command value c ω 1 and the angular speed ω 1.

The magnetic flux control unit 46 generates a command value cid1 based on the angular velocity ω 1 calculated by the estimation unit 47, a command value cvq1 (to be described later) generated by the current control unit 43, and a current measurement value iq1 (q-axis current). The command value cid1 is a command value that specifies the magnitude of the field weakening current (the current component that generates the magnetic flux in the d-axis direction) of the AC motor 15. In the case where the control performed by the control unit 4 is the normal control, the command value cid1 generated by the magnetic flux control unit 46 is a command value for adjusting the field-weakening current to 0. In the case where the control performed by the control unit 4 is the field-weakening control, the magnetic flux control unit 46 determines the command value cid1 by a determination process to be described later.

The current control unit 43 generates a command value cvd1 based on the difference between the command value cid1 generated by the magnetic flux control unit 46 and the current measurement value id1 calculated by the second coordinate converter 45. The command value cvd1 is a command value that specifies the magnitude of the d-axis voltage of the AC motor 15. The current control unit 43 determines the command value cvd1 to reduce the difference between the command value cid1 and the current measurement value id 1.

In addition, the current control unit 43 also generates a command value cvq1 based on the difference between the command value ciq1 generated by the speed control unit 42 and the current measurement value iq1 calculated by the second coordinate converter 45. Command value cvq1 is a command value that specifies the magnitude of the q-axis voltage of AC motor 15. The current control unit 43 generates the command value cvq1 to reduce the difference between the command value ciq1 and the current measurement value iq 1.

The first coordinate converter 44 coordinate-converts the command values cvd1 and cvq1 based on the rotation angle θ 1 of the AC motor 15 measured by the motor rotation measuring unit 27 to calculate the command value cv_u1、cv_v1 and cv_w1. Specifically, the first coordinate transformer 44 transforms the command value cvd1 for the magnetic field component (d-axis voltage) and the command value cvq1 for the torque component (q-axis voltage) into the command value cv corresponding to the three-phase voltages_u1、cv_v1 and cv_w1. Specifically, the command value cv_u1 corresponds to the U-phase voltage, command value cv_v1 corresponds to the V-phase voltage, and the command value cv_w1 corresponds to the W phase voltage.

The inverter circuit unit 51 will respectively correspond to the command values cv_u1、cv_v1 and cv_wThe three-phase voltage corresponding to 1 is supplied to the AC motor 15. The control unit 4 controls the electric power to be supplied to the AC motor 15 by performing Pulse Width Modulation (PWM) control on the inverter circuit section 51.

The AC motor 15 is driven by the electric power (three-phase voltage) supplied from the inverter circuit portion 51, thereby generating rotational driving force.

As a result, the control unit 4 controls the field-weakening current so that the field-weakening current flowing through the coil 141 of the AC motor 15 has a magnitude corresponding to the command value cid1 generated by the magnetic flux control unit 46. Further, the control unit 4 controls the angular velocity of the AC motor 15 so that the angular velocity of the AC motor 15 is an angular velocity corresponding to the command value c ω 1 generated by the command value generation unit 41.

The step-out detecting unit 48 detects step-out (out of synchronization) of the AC motor 15 based on the current measurement values id1 and iq1 acquired from the second coordinate converter 45 and the command values cvd1 and cvq1 acquired from the current control unit 43. When step loss is detected, the step loss detection unit 48 sends a stop signal cs1 to the inverter circuit section 51, thereby stopping the supply of electric power from the inverter circuit section 51 to the AC motor 15.

(4) Details of the field-weakening control

Next, a determination process using the command value cid1 of the magnetic flux control unit 46 will be described. In the present embodiment, the d-axis current when the field weakening occurs is referred to as a negative current.

As the command value cid1 increases, the d-axis current adjusted according to the command value cid1 increases. The d-axis current substantially transitions at 0 ampere or less (see fig. 4) except for the activation of the power tool 1, and weak magnetism is generated when the d-axis current has a negative value. When the d-axis current is negative, and as the absolute value of the d-axis current increases, the field weakening increases. The magnetic flux control unit 46 determines the command value cid1 of the d-axis current at predetermined time intervals (for example, every several tens of microseconds) by the determination process shown in fig. 3.

The control unit 4 causes a field-weakening current to flow through the coil 141 of the AC motor 15 in the case where a predetermined switching condition is satisfied. That is, in the case where the switching condition is satisfied, the control performed by the control unit 4 is the field-weakening control. The switching condition includes a condition that the AC motor 15 is operating in a high speed range. When the AC motor 15 is operating in the high speed range, roughly, the number of revolutions of the AC motor 15 is relatively high. In the present embodiment, "when the AC motor 15 is operating in the high speed range" is defined by: the rotation number of the AC motor 15 is greater than or equal to a predetermined rotation number R1 (see fig. 4), and the duty ratio of the PWM control by the control unit 4 for the inverter circuit section 51 is greater than or equal to a predetermined value. That is, the high speed range is an operation range in which the rotation number of the AC motor 15 is greater than or equal to the predetermined rotation number R1. Further, the high speed range is an operating range in which the duty ratio (modulation degree) of the PWM control is greater than or equal to a predetermined value (hereinafter referred to as "duty threshold value"). The duty ratio of the PWM control is a value obtained by dividing an ON period in one period of the PWM signal by the length of the one period. The number of revolutions of the AC motor 15 is substantially proportional to the duty ratio. The duty cycle threshold is, for example, about 0.9 or 0.95.

Further, the switching condition includes a condition that the value of the torque current (the value of the q-axis current) flowing through the coil 141 of the AC motor 15 is less than or equal to a predetermined current value J1 (see fig. 4). In the present embodiment, the control unit 4 uses the current measurement value iq1 as the value of the torque current to determine whether the switching condition is satisfied. Note that the control unit 4 may use the command value ciq1 of the value of the torque current as the value of the torque current.

As described below, it is proved that the switching condition is a condition that the angular velocity ω 1 is greater than or equal to the reference value, the current measurement value iq1 is less than or equal to the predetermined current value J1, and the command value cvq1 is greater than or equal to the reference voltage. In this case, the reference voltage corresponds to a value obtained by converting the duty threshold into a voltage.

The control unit 4 uses the angular velocity ω 1 calculated by the estimation unit 47 as a value corresponding to the rotation number of the AC motor 15. That is, as shown in fig. 3, the control unit 4 compares the angular velocity ω 1 with the reference value (step ST1) to determine whether the rotation number of the AC motor 15 is greater than or equal to the predetermined rotation number R1. The reference value is a value obtained by converting a predetermined rotation number R1 into an angular velocity. The reference value is stored in advance in, for example, a memory of a microcontroller included in the control unit 4. If the angular velocity ω 1 is smaller than the reference value (yes in step ST1), the control unit 4 continues to compare the angular velocity ω 1 with the reference value. On the other hand, if the angular velocity ω 1 is greater than or equal to the reference value (no in step ST1), the control unit 4 removes the ripple component of the current measurement value iq1 of the q-axis current (step ST 2). Specifically, the control unit 4 removes the ripple component of the current measurement value iq1 by a low-pass filter having a cutoff frequency of several tens of hertz (for example, 20 Hz).

Then, the control unit 4 compares the current measurement value iq1 with a predetermined current value J1 (see fig. 4) (step ST 3). If the measured current value iq1 is greater than the predetermined current value J1 (yes in step ST3), the magnetic flux control unit 46 increases the command value cid1 specifying the d-axis current by a predetermined amount Δ i (step ST 4). That is, the magnetic flux control unit 46 generates the command value cid1 for specifying the d-axis current larger than the command value cid1 at the time point before comparing the current measurement value iq1 with the predetermined current value J1. The predetermined amount Δ i is a fixed value determined in advance, and is stored in advance in, for example, a memory of a microcontroller included in the control unit 4.

After that, the magnetic flux control unit 46 performs the restriction processing of the command value cid1 (step ST 5). The restriction processing in this case is specifically the following processing: if the command value cid1 is smaller than the predetermined lower limit value J2 (see fig. 4), the command value cid1 is changed to the predetermined lower limit value J2, and if the command value cid1 is larger than the predetermined upper limit value, the command value cid1 is changed to the predetermined upper limit value. Here, the predetermined upper limit value is 0 ampere. The magnetic flux control unit 46 outputs the command value cid1 after the limiting process.

Further, if the current measurement value iq1 is less than or equal to the predetermined current value J1 (no in step ST3), the magnetic flux control unit 46 compares the command value cvq1 specifying the q-axis voltage with the reference voltage (step ST 6). The reference voltage is stored in advance in, for example, a memory of a microcontroller included in the control unit 4. If the command value cvq1 is greater than or equal to the reference voltage (no in step ST6), the magnetic flux control unit 46 decreases the command value cid1 that specifies the d-axis current by the predetermined amount Δ i (step ST7), and performs the limiting process (step ST5) to output the command value cid 1. In the case where no field weakening current flows through the coil 141 of the AC motor 15, decreasing the command value cid1 in step ST7 causes the field weakening current to start flowing through the coil 141. That is, the control performed by the control unit 4 is switched from the normal control to the field weakening control. In summary, the switching condition for starting the field weakening control is a condition as follows: the angular velocity ω 1 is greater than or equal to the reference value (no in step ST1), the current measurement value iq1 is less than or equal to the predetermined current value J1 (no in step ST3), and the command value cvq1 is greater than or equal to the reference voltage (no in step ST 6).

As already explained, the reference voltage corresponds to a value obtained by converting the duty threshold of the duty ratio of the PWM control into a voltage. That is, the magnetic flux control unit 46 determines whether the duty ratio of the PWM control is greater than or equal to the duty ratio threshold value by comparing the command value cvq1 with the reference voltage. If command value cvq1 is greater than or equal to the reference voltage, the duty cycle of the PWM control may be deemed to be greater than or equal to the duty cycle threshold.

In step ST6, if the command value cvq1 is smaller than the reference voltage (yes in step ST6), the magnetic flux control unit 46 increments the count number by 1 (step ST8), and compares the count number with a predetermined value (here, 100) (step ST 9). The count number used here is a count number of the number of times of determination that the command value cvq1 is smaller than the reference voltage is obtained. If the count number is less than or equal to 100 (no in step ST9), the magnetic flux control unit 46 does not increase and decrease the command value cid1, but the magnetic flux control unit 46 performs the restriction process (step ST5), thereby outputting the command value cid 1. On the other hand, if the count number is greater than 100 (yes in step ST9), the count number is initialized to 0 (step ST10), and the magnetic flux control unit 46 increases the command value cid1 by the predetermined amount Δ i (step ST 11). After that, the limiting process is performed (step ST5), and the command value cid1 is output.

In the following description, the contents of steps ST3 to ST11 are summarized. If the first condition that the current measurement value iq1 of the q-axis current is larger than the predetermined current value J1 is satisfied, the command value cid1 of the d-axis current is increased from a negative value toward 0 (step ST 4). This reduces field weakening. On the other hand, if the second condition that the current measurement value iq1 of the q-axis current is less than or equal to the predetermined current value J1 and the command value cvq1 of the q-axis voltage is greater than or equal to the reference voltage is satisfied, the command value cid1 of the d-axis current is decreased from 0 or a negative value (step ST 7). This increases the field weakening. On the other hand, if the third condition that the current measurement value iq1 of the q-axis current is less than or equal to the predetermined current value J1 and the command value cvq1 of the q-axis voltage is less than the reference voltage is satisfied, the command value cid1 of the d-axis current is increased from a negative value toward 0 every time the third condition is satisfied 100 times (step ST 11). This reduces field weakening. If the counted number of times of satisfying the third condition is less than or equal to 100, the command value cid1 of the d-axis current is maintained.

Therefore, the control unit 4 has a function of changing the magnitude of the field-weakening current in the field-weakening control. If the second condition (predetermined increase condition) is satisfied in the field weakening control, the control unit 4 performs gradual increase control of increasing the absolute value of the field weakening current with the passage of time in step ST 7. On the other hand, if the third condition (predetermined reduction condition) is satisfied in the field weakening control, the control unit 4 performs a taper control of decreasing the absolute value of the field weakening current with the elapse of time in steps ST8 to ST 11. As used herein, "passage over time" includes the aspect that: instead of changing the field weakening current as a control object by one step and stabilizing the field weakening current at the current value after the change, the field weakening current is changed by a plurality of steps and then the value of the field weakening current is stabilized. In the present embodiment, in step ST4, ST7, or ST11, the command value cid1 of the d-axis current is changed by the predetermined amount Δ i, and step ST4, ST7, or ST11 is repeated a plurality of times, thereby finally stabilizing the field-weakening current. The absolute value of the field-weakening current is gradually changed with the passage of time, thereby gradually changing the rotation number of the AC motor 15. This reduces the possibility that the operator using the electric power tool 1 feels a violation even when the number of rotations is automatically changed by the control performed by the control unit 4.

Here, if the command value cvq1 is smaller than the reference voltage (if the second condition is satisfied) in step ST6, the control unit 4 performs control (increasing control) of increasing the absolute value of the field-weakening current (d-axis current) with the passage of time in step ST 7. On the other hand, if the command value cvq1 is greater than or equal to the reference voltage (the second condition is no longer satisfied and the third condition is satisfied) in step ST6, the control unit 4 performs control (taper control) of decreasing the absolute value of the field-weakening current with the elapse of time in steps ST8 to ST 11. As described above, if the counted number of times of satisfying the third condition is less than or equal to 100, the command value cid1 of the d-axis current is maintained. Therefore, the rate of change of the command value cid1 in steps ST8 to ST11 is smaller than the rate of change of the command value cid1 in steps ST4 and ST 7. That is, the rate of increase of the command value cid1 by the taper control in the case where the third condition is continuously satisfied is smaller than the rate of increase of the command value cid1 in the case where the first condition is continuously satisfied, and is smaller than the rate of decrease of the command value cid1 by the taper control in the case where the second condition is continuously satisfied. In summary, the rate of change of the field-weakening current in the case of the gradual-decrease control is smaller than that in the case of the gradual-increase control. Therefore, for example, in the case where the length of the period in which the command value cvq1 of the q-axis voltage is smaller than the reference voltage is substantially equal to the length of the period in which the command value cvq1 of the q-axis voltage is greater than or equal to the reference voltage, as viewed from a time scale greater than or equal to a certain time scale, the field-weakening current decreases. Therefore, the pulsation (hunting) of the field-weakening current can be suppressed.

Fig. 4 shows an example of transition of various parameters of the electric power tool 1 with the passage of time in the case where the AC motor 15 is controlled based on the process shown in fig. 3. In fig. 4, "battery current" refers to the output current of the power supply 32 of the present embodiment, "battery voltage" refers to the output voltage of the power supply 32 of the present embodiment, and "iq 1" refers to the current measurement value iq1 in the electric power tool 1 of the present embodiment. Further, in fig. 4, "id 1" refers to the current measurement value id1 in the electric power tool 1 of the present embodiment, and "r 1" refers to the number of revolutions of the AC motor 15 of the electric power tool 1 of the present embodiment. Further, in fig. 4, "r 2" refers to the number of revolutions of the AC motor of the electric tool according to the comparative example of the electric tool 1 of the present embodiment. The electric power tool according to the comparative example always maintains a state in which no weak magnetic flux flows through the AC motor. That is, in the electric power tool according to the comparative example, the control performed by the control unit is always the regular control.

In this case, the electric power tool 1 is assumed to be used as an impact screwdriver or a drill screwdriver for tightening a screw. That is, a screwdriver is attached to the socket 23 of the electric power tool 1 (see fig. 2). The operator inserts the screwdriver into the screw at a time point prior to time point T0. At a time point T0, the operator provides an operation for pulling the trigger 29 of the electric power tool 1, whereby q-axis current (torque current) starts to flow through the AC motor 15, so that the AC motor 15 starts to rotate. Thereafter, the number of revolutions r1 is gradually increased according to a manipulated variable indicating the depth to which the trigger 29 is pulled. Here, the manipulated variable indicating the depth to which the trigger 29 is pulled is the largest. Therefore, the rotation number r1 increases to the upper limit within the adjustable range. In a similar manner to the electric power tool 1 of the embodiment, the electric power tool of the comparative example is also assumed to be used as an impact screwdriver or a drill screwdriver. Also in the electric power tool of the comparative example, the number of revolutions r2 is gradually increased according to the manipulated variable indicating the depth to which the trigger is pulled, and is increased to the upper limit within the adjustable range.

At a time point T1, the rotation number R1 reaches the predetermined rotation number R1. Thereafter, at a time point T2, the above switching condition is satisfied. Therefore, in the electric power tool 1 of the embodiment, the control performed by the control unit 4 is switched from the normal control to the field weakening control so that the d-axis current (field weakening current) starts to flow. That is, at and after the time point T2, the current measurement value id1 of the d-axis current is gradually decreased from 0.

As the screw is screwed into the member, the q-axis current (torque current) required to further tighten the screw may increase. As the q-axis current increases, the loss of the internal resistance of the power supply 32 (battery) increases, and thus the battery voltage decreases. Therefore, the reduction in the rotation number r1 due to the drop in the battery voltage can be compensated by flowing the d-axis current (field weakening current). That is, the reduction in the rotation number r1 can be suppressed as compared with the case where the d-axis current is not caused to flow. In other words, the rotation number r1 of the AC motor 15 according to the present embodiment is higher than the rotation number r2 according to the comparative example during the d-axis current flow.

In the electric power tool 1 of the present embodiment, at the time point T3, the magnitude of the current measurement value id1 of the d-axis current is a value close to the predetermined lower limit value J2. Through the limiting process (see step ST5), the current measurement value id1 of the d-axis current is shifted within a range of not less than the predetermined lower limit value J2.

At and after the time point T4, the current measurement value iq1 of the q-axis current is larger than the predetermined current value J1 (yes in step ST 3). Therefore, the current measurement value id1 of the d-axis current increases from a negative value toward 0. Further, near time T4, the screw is fixed to the member. The predetermined current value J1 is set to a value smaller than the current measurement value iq1 of the q-axis current (torque current) when the screw is fixed to the member. That is, when the screw is fixed to the member and the torque is relatively large, the current measurement value iq1 of the q-axis current exceeds the predetermined current value J1, and in response thereto, the control unit 4 thereby reduces the absolute value of the d-axis current. In other words, the control unit 4 reduces the field weakening current. As a result, the field weakening is reduced. The reduction of the field weakening enables the AC motor 15 to be driven by an increased torque.

At a time point T5, the magnitude of the field weakening current is 0. Further, at a time point T6, the operator sets the manipulated variable indicating the depth to which the trigger 29 is pulled to 0, so that the AC motor 15 is stopped.

According to the above-described embodiment, flowing the field-weakening current through the coil 141 of the AC motor 15 can increase the rotation number of the AC motor 15 as compared with the case where no field-weakening current is caused to flow. This can shorten the time required for the work such as tightening of screws by the electric power tool 1. In addition, it is possible to reduce the possibility that the increased number of rotations may deform the shape of the hole formed in the member as the object of punching with the electric power tool 1 serving as a drill.

Further, the performance characteristics of the electric power tool 1 may vary due to a variation in the induced electromotive voltage or a variation in the voltage (battery voltage) of the power source 32 caused by a production error of the AC motor 15. Adjusting the magnitude of the field weakening current can correct for variations in the performance characteristics of the power tool 1.

Further, in the electric power tool 1 of the present embodiment, the field weakening is reduced in the case where the current measurement value iq1 of the q-axis (torque component) is larger than the predetermined current value J1, and the field weakening eventually reaches 0. Therefore, in the case where the torque of the AC motor 15 is relatively large, a larger torque can be output.

That is, in a low speed range in which the torque of the AC motor 15 is relatively large and the number of rotations of the AC motor 15 is relatively small, the magnitude of the torque can be ensured by reducing the field weakening to 0 or a relatively small value. On the other hand, in a high speed range where the rotation number of the AC motor 15 is relatively large (at least larger than the predetermined rotation number R1 (see fig. 4)), flowing the field-weakening current can further increase the rotation number. That is, flowing the field weakening current enables the AC motor 15 to rotate at a higher rotation number than the upper limit of the rotation number in the case where the field weakening current is not caused to flow.

(5) Modification of the embodiment

Modifications of the embodiment will be listed below. The variants described below can be combined with one another accordingly.

The power tool 1 may include an operation member configured to receive an operation of, for example, a setting parameter related to the operation of the power tool 1. The operation member may include, for example, a touch panel display configured to receive an operation input and display information related to the operation.

The field weakening control and the normal control by the control unit 4 may be manually changeable by an operation provided to an operation member different from the trigger 29. For example, the control performed by the control unit 4 may be changeable by an operation provided to the touch panel display.

In the AC motor 15, the rotor 13 may include the coil 141, and the permanent magnet 131 may include the stator 14.

The electric power tool 1 is not limited to an impact screwdriver, a drill screwdriver, or an impact wrench. Alternatively, the power tool 1 may be a screwdriver or a wrench without the impact mechanism 17. Alternatively, the electric power tool 1 may be a milling cutter, a grinding machine, a cleaner, or a kind of electric power tool other than these tools.

Here, "the AC motor 15 operates in the high speed range" may be defined by the number of revolutions of the AC motor 15 being greater than or equal to the predetermined number of revolutions R1 or the duty ratio by PWM control being greater than or equal to the duty ratio threshold value.

The magnetic flux control unit 46 may control such that the rate of increase of the command value cid1 of the d-axis current in the case where the first condition is satisfied is larger than the rate of decrease of the command value cid1 of the d-axis current in the case where the second condition is satisfied. This reduces the possibility of d-axis current ripple. Such a configuration may be embodied by: for example, the command value cid1 for the d-axis current is increased each time the first condition is satisfied once, and the command value cid1 for the d-axis current is decreased each time the second condition is satisfied a plurality of times.

The condition for switching the control by the control unit 4 to the field-weakening control may be one of the following conditions, or a condition obtained by respectively combining two or more of the following conditions with each other. The plurality of conditions are, for example, a condition relating to the rotation number of the AC motor 15, a condition relating to the duty ratio of the PWM control, a condition relating to the q-axis current of the AC motor 15, and a condition relating to the q-axis voltage of the AC motor 15.

(6) Summary of the invention

The above embodiments and the like disclose the following aspects.

The electric power tool 1 according to the first aspect includes an AC motor 15 (electric motor) and a control unit 4. The AC motor 15 includes a permanent magnet 131 and a coil 141. The control unit 4 is configured to control the operation of the AC motor 15. The control performed by the control unit 4 includes field weakening control by which the control unit 4 causes a field weakening current to flow through the coil 141. The field weakening current is a current that generates a magnetic flux in the coil 141 that weakens the magnetic flux of the permanent magnet 131.

With this configuration, the control unit 4 performs field weakening control of the AC motor 15 (electric motor), thereby increasing the rotation number of the AC motor 15 as compared with the case where field weakening control is not performed.

In the electric power tool 1 of the second aspect with reference to the first aspect, the control performed by the control unit 4 includes field weakening control and regular control. The control unit 4 is configured not to cause a weak magnetic current to flow through the coil 141 in the normal control. In the case where a predetermined switching condition is satisfied, the control performed by the control unit 4 is field weakening control.

With this configuration, in the conventional control, no field weakening current flows through the coil 141, and therefore the torque of the AC motor 15 (electric motor) is larger than in the case where the control performed by the control unit 4 is the field weakening control.

In the electric power tool 1 of the third aspect referring to the second aspect, the switching condition includes a condition that the AC motor 15 (electric motor) is operating in a high speed range.

With this configuration, the control by the control unit 4 is automatically switched according to the number of revolutions of the AC motor 15 (electric motor).

In the electric power tool 1 of the fourth aspect referring to the third aspect, the high speed range is an operation range in which the number of rotations of the AC motor 15 (electric motor) is greater than or equal to a predetermined number of rotations.

With this configuration, in the case where the rotation number of the AC motor 15 (electric motor) is relatively high, the rotation number of the AC motor 15 is further increased.

In the electric power tool 1 of the fifth aspect referring to the third aspect or the fourth aspect, the control unit 4 is configured to control electric power to be supplied to the AC motor 15 (electric motor) by PWM control. The high speed range is an operating range in which the duty ratio of the PWM control is greater than or equal to a predetermined value.

With this configuration, in the case where the duty ratio of the PWM control is relatively large, and therefore the rotation number of the AC motor 15 (electric motor) is relatively high, the rotation number of the AC motor 15 is further increased.

In the electric power tool 1 of the sixth aspect with reference to any one of the second to fifth aspects, the switching condition includes a condition that the value of the torque current flowing through the coil 141 is less than or equal to a predetermined current value J1.

With this configuration, in the case where the value of the torque current is relatively small, and therefore the rotation number of the AC motor 15 is relatively high, the rotation number of the AC motor 15 (electric motor) is further increased.

In the electric power tool 1 of the seventh aspect with reference to any one of the first to sixth aspects, the control unit 4 has a function for changing the magnitude of the field-weakening current in the field-weakening control. More specifically, the control unit 4 is configured to change the magnitude of the field-weakening current in the case where the condition (the increase condition or the decrease condition) is satisfied in the field-weakening control.

This configuration enables the rotation number of the AC motor 15 (electric motor) to be controlled more finely than the case where the magnitude of the field-weakening current is constant.

In the electric power tool 1 of the eighth aspect with reference to the seventh aspect, the control unit 4 is configured to perform gradual increase control of increasing the absolute value of the field weakening current with the passage of time, in the field weakening control, in a case where a predetermined increase condition is satisfied.

With this configuration, compared to the case where the field-weakening current is changed, for example, in a binary manner, the change in the rotation number of the AC motor 15 (electric motor) is gentle, and therefore the operator easily performs work by using the electric power tool 1.

In the electric power tool 1 of the ninth aspect with reference to the seventh aspect or the eighth aspect, the control unit 4 is configured to perform, in the field weakening control, a taper-down control that reduces an absolute value of the field weakening current with the elapse of time in a case where a predetermined reduction condition is satisfied.

With this configuration, compared to the case where the field-weakening current is changed, for example, in a binary manner, the change in the rotation number of the AC motor 15 (electric motor) is gentle, and therefore the operator easily performs work by using the electric power tool 1.

In the electric power tool 1 of the tenth aspect with reference to the eighth aspect, the control unit 4 is configured to perform, in the field weakening control, gradual decrease control of decreasing the absolute value of the field weakening current with the elapse of time in a case where a predetermined decrease condition is satisfied. The predetermined decrease condition is different from the predetermined increase condition. The rate of change of the field weakening current in the taper-down control is smaller than the rate of change of the field weakening current in the taper-up control.

This configuration reduces the possibility that the weak magnetic current pulsates with the pulsation of the parameter relating to the predetermined increase condition and the predetermined decrease condition.

The structure other than that of the first aspect is not a necessary structure of the electric power tool 1, and may be omitted accordingly.

Description of the reference numerals

1 electric tool

4 control unit

15 AC motor (electric motor)

131 permanent magnet

141 coil

J1 predetermined current value